U.S. patent application number 15/512825 was filed with the patent office on 2017-10-12 for die-casting process method for die-cast molding of metal in semi-solid state.
This patent application is currently assigned to ZHUHAI RUNXINGTAI ELECTRICAL CO., LTD. The applicant listed for this patent is ZHUHAI RUNXINGTAI ELECTRICAL CO., LTD. Invention is credited to Gunan LI, Huaide REN, Victor WANG.
Application Number | 20170291218 15/512825 |
Document ID | / |
Family ID | 52151063 |
Filed Date | 2017-10-12 |
United States Patent
Application |
20170291218 |
Kind Code |
A1 |
REN; Huaide ; et
al. |
October 12, 2017 |
DIE-CASTING PROCESS METHOD FOR DIE-CAST MOLDING OF METAL IN
SEMI-SOLID STATE
Abstract
A die-casting process method for die-cast molding of a metal in
a semi-solid state, wherein a semi-solid state die-casting machine
is used as a processing device and a pulper is used as a device for
preparing and delivering a slurry in a semi-solid state; the method
comprises the steps: spraying a mold release agent and mold
clamping; melting the raw material and keeping the temperature;
adding a metal modificator into the molten raw material to prepare
the slurry in a semi-solid state; transferring the slurry in a
semi-solid state into a mold by the pulper; die-casting, opening
the mold and exporting a die-cast; removing the sprue to obtain the
final die-cast. In the process method, a metal modificator is added
to the liquid metal raw material during the preparation of the
slurry in a semi-solid state so as to generate more crystal nuclei,
so that die-cast products have better mechanical properties; by way
of die-casting the slurry in a semi-solid state, during mold
stripping the die-cast is low in temperature and small in
deformation quantity, and the best shapes and surface smoothness of
the product can be guaranteed; and the die-cast is compact
interiorly with producing air holes, and the best interior
structure and mechanical properties of the die-cast product are
guaranteed.
Inventors: |
REN; Huaide; (Zhuhai,
CN) ; WANG; Victor; (Zhuhai, CN) ; LI;
Gunan; (Zhuhai, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ZHUHAI RUNXINGTAI ELECTRICAL CO., LTD |
Zhuhai |
|
CN |
|
|
Assignee: |
ZHUHAI RUNXINGTAI ELECTRICAL CO.,
LTD
Zhuhai
CN
|
Family ID: |
52151063 |
Appl. No.: |
15/512825 |
Filed: |
September 17, 2015 |
PCT Filed: |
September 17, 2015 |
PCT NO: |
PCT/CN2015/089861 |
371 Date: |
March 20, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22D 18/02 20130101;
C22C 21/04 20130101; B22D 17/08 20130101; B22D 17/007 20130101;
B22D 21/007 20130101; B22D 21/04 20130101 |
International
Class: |
B22D 17/00 20060101
B22D017/00; B22D 18/02 20060101 B22D018/02; B22D 17/08 20060101
B22D017/08 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 23, 2014 |
CN |
201410492077.5 |
Claims
1. A die-casting process method for die-cast molding of semisolid
metal, characterized in that, in the die-casting process method, a
semisolid die-casting machine is used as the processing device, and
a pulper is used as the device for preparing and delivering
semisolid slurry; the device layout of the die-casting process
method is as follows: the pulper is arranged on the left side of
the semisolid die-casting machine, a sprayer configured to spray
mold release agent to a mold is arranged on the right side of the
semisolid die-casting machine, and an extractor configured to
extract a die-cast out of the mold is arranged on the front side of
the semisolid die-casting machine, the right side of the extractor
is coordinated with a conveyor belt, an operating bench is arranged
at the right end of the conveyor belt, and an oil press configured
to stamp to remove a sprue on the die-cast is provided on the
operating bench; and the die-casting process method comprises the
steps of: (1) mounting the mold on the semisolid die-casting
machine, spraying the mold release agent onto the surface of the
mold with the sprayer, and then closing the mold; (2) melting metal
raw material with a heating furnace, and putting the liquid metal
raw material into a holding furnace for storage, wherein the metal
raw material is a metal raw material of aluminum alloy; (3)
preparing semisolid slurry from the liquid metal raw material in
the holding furnace by the pulper; (4) conveying the semisolid
slurry into the mold of the semisolid die-casting machine by the
pulper; (5) die-casting by the semisolid die-casting machine, and
then opening the mold, extracting the die-cast out of the mold with
the extractor, and exporting the die-cast by placing it on the
conveyor belt; and (6) conveying the die-cast to the operating
bench by the conveyor belt, and stamping to remove the sprue on the
die-cast by the oil press to obtain the final die-cast product.
2. The die-casting process method according to claim 1,
characterized in that, in the step (5), the semisolid die-casting
machine is a 1000T horizontal cold chamber die-casting machine,
with a die-casting temperature of 586.degree. C. to 594.degree. C.,
a die-casting speed of 4.2 m/s, a system pressure of 15.5 MPa, and
a boost pressure of 29 MPa.
3. The die-casting process method according to claim 2,
characterized in that, in the step (3), mass percentages of the
components in the liquid metal raw material are: 6-7.5% of silicon,
0.3-1.7% of copper, 0.2-2.5% of zinc, 0.4-2.2% of nickel, 0.2-0.7%
of magnesium, 0.2-1.3% of iron, with the balance of aluminum.
4. The die-casting process method according to claim 3,
characterized in that, in the step (3), a method for preparing the
semisolid slurry by the pulper comprises the steps of: keeping the
temperature of the liquid metal raw material in the holding furnace
12.degree. C. to 23.degree. C. higher than its liquidus; placing
the molten metal raw material in the holding furnace into a ladle
by the pulper, then placing a solid metal modifier into the ladle,
and the metal modifier in the ladle being melted after absorbing
the heat of the liquid metal raw material, thus to cool the liquid
metal raw material and generate a large number of crystal nuclei,
to obtain the semisolid slurry; and blowing, at a speed of 13
L/min, argon gas into the metal raw material in the ladle while
adding the metal modifier, to accelerate mixing and cooling,
wherein the dosage of the metal modifier is 1.5% to 3.8% of the
mass of the metal raw material in the ladle.
5. The die-casting process method according to claim 4,
characterized in that, the components of the metal modifier are the
same as those of the liquid metal raw material.
6. The die-casting process method according to claim 4,
characterized in that, the metal modifier comprises the following
components: silicon, copper, manganese, magnesium, zinc, titanium,
lead and aluminum, at a mass ratio of (6.55 to 6.90): (0.22 to
0.85): (0.003 to 0.008): (0.15 to 0.75): (0.03 to 0.075): (0.06 to
0.1): (0.03 to 0.05): (91.7 to 92.8).
7. The die-casting process method according to claim 6,
characterized in that, the metal modifier comprises the following
components: silicon, copper, manganese, magnesium, zinc, titanium,
lead and aluminum, at a mass ratio of 6.70: 0.57: 0.007: 0.38:
0.047: 0.08: 0.04: 92.5.
Description
[0001] The application claims the priority of the Chinese Patent
Application No. 201410492077.5, titled " (DIE-CASTING PROCESS
METHOD FOR DIE-CAST MOLDING OF METAL IN SEMI-SOLID STATE)", filed
to the SIPO on Sep. 23, 2014, the disclosure of which is hereby
incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a die-casting process
method of metal, and in particular to a die-casting process method
for die-cast molding of semisolid metal.
BACKGROUND ART
[0003] An ordinary high-speed high-pressure injection molding
process requires fast mold filling of molten aluminum at a high
temperature of about 680.degree. C. During the molding, it is
likely to cause internal shrinkage cavity and pore defects due to
air entrapment, and accordingly, it is likely to cause poor air
tightness in a casting when processed and assembled. After being
molded by die-casting, a product is subject to significant thermal
deformation during cooling, and the deformation of a die-cast blank
can reach about 2 mm. During the cleaning, manual sizing is
required to guarantee the planarity that is necessary to the
subsequent processing, thus resulting in difficulties in processing
and positioning and also adversely impacting the quality and
accuracy of the product.
[0004] At present, products prepared by ordinary die-casting
processes are instable in internal quality, and the assembled
products with poor air tightness take share of about 10%. The
cleaning of the die-casts is highly labor intensive and it is
difficult to guarantee the appearance quality. This becomes a
bottleneck procedure for die-casting production and restricts the
rapid development of the die-casting industry.
Contents of the Present Invention
[0005] A technical problem to be solved by the present invention is
to overcome the defects of the prior art, and to provide a
die-casting process method for die-cast molding of semisolid metal.
With regard to this method, by die-casting of the semisolid slurry,
the die-cast product is compact interiorly, without any pores
formed, the deformation of a die-cast blank is extremely small,
complex surface treatment is not required for the die-cast, and the
best quality and performance of the product can be guaranteed.
[0006] The present invention provides a die-casting process method
for die-cast molding of semisolid metal. In the die-casting process
method, a semisolid die-casting machine is used as the processing
device, and a pulper is used as the device for preparing and
delivering semisolid slurry; the device layout of the die-casting
process method is as follows: the pulper is arranged on the left
side of the semisolid die-casting machine, a sprayer configured to
spray mold release agent to a mold is arranged on the right side of
the semisolid die-casting machine, and an extractor configured to
extract a die-cast out of the mold is arranged on the front side of
the semisolid die-casting machine; the right side of the extractor
is coordinated with a conveyor belt, an operating bench is arranged
at the right end of the conveyor belt, and an oil press configured
to stamp to remove a sprue on the die-cast is provided on the
operating bench; and
[0007] the die-casting process method includes the steps of:
[0008] (1) mounting the mold on the semisolid die-casting machine,
spraying the mold release agent onto the surface of the mold with
the sprayer, and then closing the mold;
[0009] (2) melting metal raw material with a heating furnace, and
putting the liquid metal raw material into a holding furnace for
storage, wherein the metal raw material is a metal raw material of
aluminum alloy;
[0010] (3) preparing semisolid slurry from the liquid metal raw
material in the holding furnace by the pulper;
[0011] (4) conveying the semisolid slurry into the mold of the
semisolid die-casting machine by the pulper;
[0012] (5) die-casting by the semisolid die-casting machine, and
then opening the mold, extracting the die-cast out of the mold with
the extractor, and exporting the die-cast by placing it on the
conveyor belt; and
[0013] (6) conveying the die-cast to the operating bench by the
conveyor belt, and stamping to remove the sprue on the die-cast by
the oil press to obtain the final die-cast product.
[0014] Wherein, in the step (5), the semisolid die-casting machine
is a 1000T horizontal cold chamber die-casting machine, with a
die-casting temperature of 586.degree. C. to 594.degree. C., a
die-casting speed of 4.2 m/s, a system pressure of 15.5 MPa, and a
boost pressure of 29 MPa.
[0015] Wherein, in the step (3), mass percentages of the components
in the liquid metal raw material are: 6-7.5% of silicon, 0.3-1.7%
of copper, 0.2-2.5% of zinc, 0.4-2.2% of nickel, 0.2-0.7% of
magnesium, 0.2-1.3% of iron, with the balance of aluminum.
[0016] Wherein, in the step (3), a method for preparing the
semisolid slurry by the pulper comprises the steps of: keeping the
temperature of the liquid metal raw material in the holding furnace
12.degree. C. to 23.degree. C. higher than its liquidus; placing
the molten metal raw material in the holding furnace into a ladle
by the pulper, then placing a solid metal modifier into the ladle,
and the metal modifier in the ladle being melted after absorbing
the heat of the liquid metal raw material, thus to cool the liquid
metal raw material and generate a large number of crystal nuclei,
to obtain the semisolid slurry; and blowing, at a speed of 13
L/min, argon gas into the metal raw material in the ladle while
adding the metal modifier, to accelerate mixing and cooling,
wherein the dosage of the metal modifier is 1.5% to 3.8% of the
mass of the metal raw material in the ladle.
[0017] Wherein, the components of the metal modifier are the same
as those of the liquid metal raw material.
[0018] Wherein, the metal modifier comprises the following
components: silicon, copper, manganese, magnesium, zinc, titanium,
lead and aluminum, at a mass ratio of (6.55 to 6.90): (0.22 to
0.85): (0.003 to 0.008): (0.15 to 0.75): (0.03 to 0.075): (0.06 to
0.1): (0.03 to 0.05): (91.7 to 92.8).
[0019] Wherein, the metal modifier comprises the following
components: silicon, copper, manganese, magnesium, zinc, titanium,
lead and aluminum, at a mass ratio of 6.70: 0.57: 0.007: 0.38:
0.047: 0.08: 0.04: 92.5.
[0020] According to the above technical solution, the following
beneficial technical effects can be found.
[0021] (1) With regard to the die-casting process method for
die-cast molding of semisolid metal of the present invention, by
die-casting of the semisolid slurry, the die-cast product is
compact interiorly, without any pores formed, and the best interior
structure and mechanical properties of the die-cast product are
guaranteed, and the quality of the product is guaranteed.
[0022] (2) With regard to the die-casting process method for
die-cast molding of semisolid metal of the present invention, by
die-casting of the semisolid slurry, compared with the traditional
high-speed high-pressure injection molding process, the die-cast,
when extracted out of the mold, is lower in temperature, and the
die-cast blank, when extracted out of the mold, has a certain
mechanical strength. In contrast, a die-cast, prepared by the
traditional liquid die-casting processes, when extracted out of the
mold, has a higher temperature and is likely to deform when
extracted out of the mold. The deformation of the die-cast blank of
the present invention is extremely small, and complex surface
treatment is not required for the die-cast, so that the best shape
and surface smoothness of the product can be guaranteed.
[0023] (3) With regard to the die-casting process method for
die-cast molding of semisolid metal of the present invention, by a
semisolid die-casting process, the die-cast product has many
spherical crystals and the die-casting has better mechanical
properties.
DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a schematic diagram of an device layout of a
die-casting process method for die-cast molding of semisolid metal
of the present invention; and
[0025] FIG. 2 is a flow diagram of the die-casting process method
of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0026] In order to make the objectives, technical solutions and
advantages of the present invention clearer, the present invention
will be further described in detail by way of Examples.
EXAMPLE 1
[0027] A technical solution employed by the present invention is a
die-casting process method for die-cast molding of semisolid metal.
In the die-casting process method, a semisolid die-casting machine
is used as the processing device, and a pulper is used as the
device for preparing and delivering semisolid slurry; the device
layout of the die-casting process method is as follows: the pulper
is arranged on the left side of the semisolid die-casting machine,
a sprayer configured to spray a mold release agent to a mold is
arranged on the right side of the semisolid die-casting machine,
and an extractor configured to extract a die-cast out of the mold
is arranged on the front side of the semisolid die-casting machine;
the right side of the extractor is coordinated with a conveyor
belt, an operating bench is arranged at the right end of the
conveyor belt, and an oil press configured to stamp to remove a
sprue on the die-cast is provided on the operating bench;
[0028] The die-casting process method comprises the steps of:
[0029] (1) mounting the mold on the semisolid die-casting machine,
spraying the mold release agent onto the surface of the mold with
the sprayer, and then closing the mold;
[0030] (2) melting metal raw material with a heating furnace, and
putting the liquid metal raw material into a holding furnace for
storage, where the metal raw material is a metal raw material of
aluminum alloy;
[0031] (3) preparing semisolid slurry from the liquid metal raw
material in the holding furnace by the pulper; placing the molten
metal raw material into a ladle by the pulper, then placing a solid
metal modifier into the liquid metal raw material in the ladle,
thus to cool the liquid metal raw material and generate a large
number of crystal nuclei, to obtain the semisolid slurry, where
mass percentages of the components in the liquid metal raw material
are: 6-7.5% of silicon, 0.3-1.7% of copper, 0.2-2.5% of zinc,
0.4-2.2% of nickel, 0.2-0.7% of magnesium, 0.2-1.3% of iron, with
the balance of aluminum;
[0032] A method for preparing the semisolid slurry by the pulper
comprises the steps of: keeping the temperature of the liquid metal
raw material in the holding furnace 12.degree. C. to 23.degree. C.
higher than its liquidus; placing the molten metal raw material in
the holding furnace into a ladle by the pulper, then placing a
solid metal modifier into the ladle, and the metal modifier in the
ladle being melted after absorbing the heat of the liquid metal raw
material, thus to cool the liquid metal raw material and generate a
large number of crystal nuclei, to obtain the semisolid slurry; and
blowing, at a speed of 13 L/min, argon gas into the metal raw
material in the ladle while adding the metal modifier, to
accelerate mixing and cooling, where the dosage of the metal
modifier is 1.8% of the mass of the metal raw material in the
ladle;
[0033] The metal modifier comprises the following components:
silicon, copper, manganese, magnesium, zinc, titanium, lead and
aluminum, at a mass ratio of 6.70: 0.57: 0.007: 0.38: 0.047: 0.08:
0.04: 92.5;
[0034] (4) conveying the semisolid slurry into the mold of the
semisolid die-casting machine by the pulper, where the semisolid
slurry is fast molded by die-casting more easily because the
temperature thereof is lower than that of the molten metal slurry,
therefore, the temperature of the semisolid slurry after being
molded by die-casting is relatively low, and the die-cast, when
extracted out of the mold, is of a certain mechanical strength and
will not deform when extracted out of the mold due to an
excessively high temperature which would cause its shape to be
changed, so that the surface smoothness and accuracy specification
of the die-cast products are guaranteed, no manual polishing in the
subsequent processing is required to reshaping the products;
[0035] (5) die-casting by the semisolid die-casting machine, and
then opening the mold, extracting the die-cast out of the mold with
the extractor, and exporting the die-cast by placing it on the
conveyor belt, where the semisolid die-casting machine is a 1000T
horizontal cold chamber die-casting machine, with a die-casting
temperature of 586.degree. C. to 594.degree. C., a die-casting
speed of 4.2 m/s, a system pressure of 15.5 MPa, and a boost
pressure of 29 MPa; and
[0036] (6) conveying the die-cast to the operating bench by the
conveyor belt, and stamping to remove the sprue on the die-cast by
the oil press to obtain the final die-cast product.
[0037] Three die-cast products are randomly sampled from the
aluminum alloy die-cast products prepared in the Example 1, and
then tested in terms of performance. The test results are as shown
in Table 1. The specific test method includes the following
steps.
[0038] (1) Mechanical properties: a standard sample with a diameter
of 10 mm is tested at room temperature by using a tensile testing
machine by a room temperature tensile test method (GB/T228.1). The
specific test results are as shown in Table 1.
[0039] (2) Heat-conductivity properties: the heat-diffusivity is
tested by an LFA447Nanoflash instrument (a flash heat-conductivity
analyzer) in accordance with ASTME1461 Standard; and the specific
heat capacity is tested by power-compensated differential scanning
calorimetry DSC8000.
[0040] Heat-conductivity=heat-diffusivity * specific heat capacity
* density; and the test results are as shown in Table 1.
[0041] (3) Planarity: Z-coordinates of 14 points on a plane are
tested by a three-coordinate test instrument to obtain the
planarity data. The test results are as shown in Table 1.
TABLE-US-00001 TABLE 1 Items Die-cast 1 Die-cast 2 Die-cast 3
Mechanical Tensile strength 182.3 164.6 175.7 properties MPa Break
5.1 5.7 5.3 elongation % Heat-conducting Heat-conductivity 145.3
152.5 147.1 performance W/(m k) Planarity Planarity of 0.31/(420 *
220) 0.30/(420 * 220) 0.30/(420 * 220) die-casting plane mm
[0042] It can be seen from the test data in Table 1 that the
product obtained in the Example 1 of the present invention has
preferable mechanical properties, heat-conductivity and planarity,
with excellent mechanical strength, very good planarity, and
leading product performance compared with similar die-cast
products.
[0043] Finally, it should be noted that: obviously, the above
Examples are merely examples provided for clearly illustrating the
present invention, but not for limiting the embodiments. For a
person of ordinary skill in the art, variations or modifications in
other different forms may be made on the basis of the above
illustration. It is neither necessary nor able to exhaustively list
all of the embodiments. All obvious variations or modifications
derived accordingly should be regarded as falling into the
protection scope of the present invention.
[0044] The above description is merely a preferred example of the
present invention, and certainly not for limiting the protection
scope of the present invention. Therefore, the equivalent
variations made in accordance with the claims of the present
invention are still within the protection scope of the present
invention.
INDUSTRIAL APPLICABILITY
[0045] (1) With regard to the die-casting process method for
die-cast molding of semisolid metal of the present invention, by
die-casting of the semisolid slurry, the die-cast product is
compact interiorly, without any pores formed, and the best interior
structure and mechanical properties of the die-cast product are
guaranteed, and the quality of the product is guaranteed.
[0046] (2) With regard to the die-casting process method for
die-cast molding of semisolid metal of the present invention, by
die-casting of the semisolid slurry, compared with the traditional
high-speed high-pressure injection molding process, the die-cast,
when extracted out of the mold, is lower in temperature, and the
die-cast blank, when extracted out of the mold, has a certain
mechanical strength. In contrast, a die-cast, prepared by the
traditional liquid die-casting processes, when extracted out of the
mold, has a higher temperature and is likely to deform when
extracted out of the mold. The deformation of the die-cast blank of
the present invention is extremely small, and complex surface
treatment is not required for the die-cast, so that the best shape
and surface smoothness of the product can be guaranteed.
[0047] (3) With regard to the die-casting process method for
die-cast molding of semisolid metal of the present invention, by a
semisolid die-casting process, the die-cast product has many
spherical crystals and the die-casting has better mechanical
properties.
* * * * *